Bearing device with integrated electrical insulation, in particular for an electric motor or machine

ABSTRACT

A bearing device includes a first ring and a second ring mounted for relative rotation and an insulating sleeve mounted on the second ring. The insulating sleeve incudes a socket and an electrically insulating liner, the liner contacting the second ring. The socket includes an outer surface and an inner surface opposite the outer surface, and the outer surface and the inner surface delimit a radial thickness of the socket. The insulating liner is overmolded on the second ring of the bearing and on the outer surface and/or the inner surface of the socket. The socket and the insulating liner are shaped such that the insulating liner is prevented from moving circumferentially relative to the socket.

CROSS-REFERENCE

This application claims priority to French patent application no. 2200141 filed on Jan. 10, 2022, the contents of which are fully incorporated herein by reference.

TECHNOLOGICAL FIELD

The present disclosure is directed to the field of bearings used in electric motors, electric machines and associated equipment.

BACKGROUND

In an electric motor or machine, at least one rolling bearing is mounted between the housing of the electric motor or machine and the rotary shaft so as to support this shaft. In operation, when the shaft is rotating, a difference in electrical potential can arise between the shaft and the housing of the electric motor or machine. This can cause an electric current to flow between the inner ring of the rolling bearing, which is rigidly secured to the shaft, and the outer ring of the rolling bearing, which is rigidly secured to the housing.

The electric current passing through the components of the rolling bearing can damage these components, in particular the rolling elements and the raceways formed on the inner and outer rings. The electrical discharge can also give rise to an undesirable vibration. To overcome these drawbacks, it is known practice to use ceramic rolling elements instead of steel rolling elements (which steel rolling elements are generally made from the same steel as the bearing rings).

Bearings having steel rings and ceramic rolling elements are generally referred to as “hybrid rolling bearings.” However, such a hybrid rolling bearing is relatively expensive. It would therefore be desirable to provide a simple and inexpensive way to address the foregoing problems.

SUMMARY

The disclosure is directed to a bearing device comprising a bearing having a first ring and a second ring that can rotate relative to one another. According to a general feature, the device further comprises at least one insulating sleeve mounted on the second ring of the bearing.

The insulating sleeve has a socket and an insulating liner interposed radially between the second ring of the bearing and the socket. The insulating liner is made of an electrically insulating material. The socket has an outer surface and an inner surface opposite the outer surface, which delimit the radial thickness of the socket.

According to another general feature, the insulating liner is overmolded on the second ring of the bearing and at least on one of the outer and inner surfaces of the socket. The outer or inner surface of the socket is configured to retain, in the circumferential direction, the insulating liner relative to the surface by having a shape complementary to that of the insulating liner.

There is therefore provided a bearing device with integrated electrical insulation which is inexpensive compared to conventional hybrid rolling bearings. Moreover, the device is easy to manufacture and to assemble in the associated electric motor or machine.

Furthermore, the insulating liner is not exposed to impacts as it is arranged radially between the second ring of the bearing and the socket. Moreover, if the insulating liner is made of synthetic material or elastomeric material, the device will be less sensitive to temperature changes. Moreover, as the insulating liner is overmolded, it is attached to the second ring and to the socket without any additional element or particular machining of the second ring of the bearing for mounting the insulating liner. It is thus possible to use a bearing having standard first and second rings. This reduces the cost of the device.

Furthermore, the configuration of the surface of the socket further enhances the rigid securing to the insulating liner by complementarity of shapes. The risk of relative movement between the insulating liner and the socket in the circumferential direction is especially limited in particular in the event of temperature changes.

According to a first design, the surface of the socket has at least one recess inside which extends a protuberance (protrusion) for attaching the insulating liner, with a shape complementary to the recess. The attachment protuberance or protuberances are formed inside the recess or recesses in the surface of the socket during overmolding. The recess may be in the form of a notch. As a variant, the recess may be in the form of a groove. In this case, the groove may extend axially. Alternatively, the groove may extend helically.

The groove or the notch may extend from one of the end faces of the socket towards the other end face. The groove or the notch may open out on the other face or be axially at a distance from the latter. Alternatively, the groove or the notch may be at a distance from the two end faces of the socket. In other words, the groove or the notch in this case does not open out on the end faces of the socket.

The recess or recesses in the surface of the socket are formed in the radial thickness of the socket. This recess or these recesses are preferably blind—that is, they do not extend all the way through the side wall of the recess. Alternatively, it is however possible to envisage one or more through-recesses.

According to a second design, the surface of the socket has at least one protuberance protruding into a notch or opening in the insulating liner which notch or opening has a shape complementary to that of the protuberance. The second design may replace the first design or be combined with the first design.

According to a third design, the outer surface of the socket has a cylindrical shape and a central longitudinal axis and the inner surface of the socket has a cylindrical shape and a central longitudinal axis that is offset from the central longitudinal axis of the outer surface. The third design may replace the first or second design or be combined with the first design and/or with the second design.

In one particular embodiment, the socket is made of metal. The socket can thus be easily machined to a predetermined radial tolerance.

In one embodiment, the insulating liner covers the whole of the surface of the socket. In this case, the insulating liner entirely covers the surface of the socket in the axial direction and in the circumferential direction.

The second ring of the bearing comprises two opposite end faces axially delimiting the inner and outer surfaces. In one embodiment, the insulating liner may be overmolded at least partially onto one or both of the end faces.

According to a first design, the socket delimits the outer surface of the device. In this case, the second ring is the outer ring of the bearing.

According to a second alternative design, the socket delimits the inner surface of the device. In this case, the second ring is the inner ring of the bearing.

In one particular embodiment, the bearing comprises at least one row of rolling elements arranged between raceways of the first and second rings. The rolling elements may be made of metal.

The disclosure also relates to an electric motor comprising a housing, a shaft and at least one bearing device as defined above, mounted radially between the housing and the shaft.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be better understood on studying the detailed description of embodiments, given by way of non-limiting examples and illustrated by the appended drawings.

FIG. 1 is a axial sectional of a bearing device according to a first embodiment of the disclosure.

FIG. 2 is a perspective view of a socket of the bearing device of FIG. 1 .

FIG. 3 is a perspective view of a socket of a bearing device according to a second embodiment of the present disclosure.

FIG. 4 is a perspective view of a socket of a bearing device according to a third embodiment of the present disclosure.

FIG. 5 is a perspective view of a socket of a bearing device according to a fourth embodiment of the present disclosure.

FIG. 6 is an axial sectional view of a bearing device according to a fifth embodiment of the present disclosure.

FIG. 7 is a perspective view of the socket of the bearing device of FIG. 6 .

FIG. 8 is a radial sectional view of a bearing device according to a sixth embodiment of the present disclosure.

DETAILED DESCRIPTION

The bearing device shown in FIG. 1 comprises a bearing 10 having a first ring 12 and a second ring 14 that can rotate relative to one another about the axis X-X′ of the bearing. In the embodiment shown, the first ring 12 is the inner ring of the bearing and the second ring 14 is the outer ring. As described in more detail below, the bearing device is designed in such a way as not to conduct electrical current. The bearing device has integrated electrical insulation.

The inner 12 and outer 14 rings of the bearing are concentric and extend axially along the axis X-X′ of the bearing. The inner 12 and outer 14 rings are solid and are made of steel.

In the embodiment shown, the bearing 10 also comprises a row of steel rolling elements 16, in this case balls, interposed radially between the inner 12 and outer 14 rings. The bearing 10 also comprises a cage 17 for maintaining regular circumferential spacing between the rollers 16. The bearing 10 may also have seals or sealing flanges.

The inner ring 12 comprises a cylindrical bore 12 a, a cylindrical axial outer surface 12 b radially opposite the bore, and two radially opposite end faces (not referenced) axially delimiting the bore and the outer surface. The bore 12 a and the outer surface 12 b delimit the radial thickness of the inner ring 12. The inner ring 12 further comprises an inner raceway 18 for the rolling elements 16 which is formed on the outer surface 12 b. The raceway 18 is directed radially outwards.

The outer ring 14 comprises a cylindrical axial outer surface 14 a, a cylindrical bore 14 b radially opposite the outer surface 14 a, and two opposite radial end faces 14 c, 14 d axially delimiting the bore and the outer surface. The outer surface 14 a and the bore 14 b delimit the radial thickness of the outer ring 14. The outer ring 14 further comprises an outer raceway 20 for the rolling elements 16 which is formed on the bore 14 b. The raceway 20 is directed radially inwards.

The bearing device also comprises an electrically insulating sleeve 22 mounted on the outer ring 14. The insulating sleeve 22 is mounted on the outer surface 14 a of the outer ring 14 and is rigidly secured to the outer ring 14. The insulating sleeve 22 comprises a socket 24 and an insulating liner 26 interposed radially between the outer ring 14 and the socket 24. The insulating liner 26 is overmolded on the outer ring 14 and on the socket 24.

The socket 24 is annular and extends axially. The socket 24 is made in one piece. The socket 24 comprises a cylindrical axial outer surface 24 a, a cylindrical bore 24 b radially opposite the outer surface 24 a, and two opposite radial end faces 24 c, 24 d axially delimiting the bore and the outer surface. The outer surface 24 a and the bore 24 b delimit the radial thickness of the socket 24. The outer surface 24 a of the socket delimits the outer surface of the bearing device 10. In other words, the outer surface 24 a defines the outside diameter of the bearing device 10.

As can be seen in FIGS. 1 and 2 , the bore 24 b of the socket has a first group of notches 28 made axially on one side of the socket, and a second group of notches 30 made axially on the opposite side of the socket. In the embodiment shown, the notches 28, 30 are identical. The notches 28, 30 extend radially outwards from the bore 24 b of the socket. In the embodiment shown, the notches 28, 30 do not extend all the way through the radial thickness of the socket 24; that is, the notches 28, 30 are blind. Alternatively, the notches 28, 30 could be through-notches.

In the embodiment shown, the notches 28 and 30 extend axially from the end faces 24 c and 24 d of the socket and have a limited axial dimension. Alternatively, the notches 28, 30 could be formed in the bore 24 b of the socket at a distance from the end faces 24 c, 24 d.

In the embodiment shown, the notches 28, 30 of a group are regularly spaced apart from one another in the circumferential direction but they also could be spaced in an irregular manner. In another variant embodiment, a single notch 28, 30 could be provided on each side of the socket, or one or more notches could be provided on one side of the socket.

In the embodiment shown, each notch 28 of a group is offset in the circumferential direction relative to the notches 30 of the other group. However, in the alternative, the notches 28 at one axial end of the socket could be aligned axially with the notches 30 at the other end.

In the embodiment shown, the notches 28, 30 have a polygonal shape, in this case square, with a view to simplifying manufacturing. As a variant, the notches 28, 30 may have other shapes, for example oval, etc.

The socket 24 is advantageously made of metal. Thus, the outer surface 24 a of the socket can be easily machined to a predetermined tolerance if needed. Preferably, the socket 24 is made of steel. The socket 24 may be obtained from a sheet metal blank by cutting, pressing and rolling. Alternatively, the socket 24 may be obtained from a tube or from forged and/or rolled and/or sintered blanks. The notches 28, 30 may for example be formed by punching or machining.

The insulating liner 26 is made of an electrically insulating material. The insulating liner 26 may for example be made of synthetic material, such as polyether ether ketone (PEEK) or nylon-46 (PA46), or may be made of elastomeric material, for example rubber.

The insulating liner 26 is interposed radially between the outer surface 14 a of the outer ring and the bore 24 b of the socket. The insulating liner 26 at least partially covers the outer surface 14 a of the outer ring. In this embodiment, the insulating liner 26 entirely covers the outer surface 14 a with respect to the axial and circumferential directions. The insulating liner 26 also at least partially covers the bore 24 b of the socket. In this embodiment, the insulating liner 26 entirely covers the bore 24 b with respect to the axial and circumferential directions.

As stated above, the insulating liner 26 is overmolded on the outer ring 14 of the bearing and on the socket 24. The insulating liner 26 is overmolded on the outer surface 14 a of the outer ring 14 and on the bore 24 b of the socket 24. The insulating layer is connected to the outer ring 14 and/or the bearing by material bonding and/or by an interference fit.

The insulating liner 26 is annular and extends axially. The insulating liner 26 comprises a cylindrical axial outer surface 26 a, a cylindrical bore 26 b radially opposite the outer surface 26 a, and two opposite radial end faces 26 c, 26 d axially delimiting the bore and the outer surface. The outer surface 26 a and the bore 26 b delimit the radial thickness of the insulating liner 26. The outer surface 26 a is in radial contact with the bore 24 b of the socket. The bore 26 b is in radial contact with the outer surface 14 a of the outer ring.

In the embodiment shown, the faces 14 c, 26 c, 24 c of the outer ring, the insulating liner and the socket are coplanar, and the faces 14 d, 26 d, 24 d of the outer ring, the insulating liner and the socket are coplanar.

Alternative arrangements can also be used. For example, the insulating liner 26 could have an axial dimension smaller than that of the outer ring and be axially set back from the faces 14 c, 14 d of the outer ring. Alternatively, the insulating liner 26 could have an axial dimension larger than that of the outer ring and protrude axially beyond the faces 14 c, 14 d of the outer ring. In this case, the insulating liner 26 may at least partially cover these faces 14 c, 14 d. As a variant, the insulating liner 26 could at least partially cover the faces 24 c, 24 d of the socket.

In another alternative or in combination with the features mentioned above, the socket 24 could protrude axially beyond the insulating liner 26 relative to the faces 26 c and 26 d, or be axially set back from these faces.

The insulating liner 26 also comprises a plurality of protuberances 32, 34 extending radially outwards from the outer surface 26 a and each received in one of the notches 28, 30 of the socket. Each protuberance 32, 34 has a shape complementary to the associated notch 28, 30. Each protuberance 32, 34 comes into contact against the inner edge of the associated notch 28, 30. The protuberances 32, 34 protrude relative to the outer surface 26 a of the insulating liner. The protuberances 32, 34 are formed on the outer surface 26 a during overmolding of the insulating liner 26.

A method of producing the above bearing device is described below.

In a first step, the bearing 10 and the socket 24 are mounted inside a mold which is provided for overmolding the insulating liner 26. In this position mounted inside the mold, the socket 24 is radially spaced from the outer ring 14 of the bearing.

Next, during a second successive step, the insulating liner 26 is overmolded both on the outer ring 14 of the bearing and on the socket 24. As stated above, the protuberances 32, 34 of the insulating liner which promote attachment to the socket 24 are formed during this step.

Lastly, the bearing device, which is in the form of a unitary assembly, is removed from the mold.

In this embodiment, the notches 28, 30 on the bore 24 b of the socket form recesses inside each of which extends a complementary protuberance 32, 34 of the insulating liner.

As a variant, these recesses on the bore 24 b of the socket could have different shapes.

For example, in the embodiment shown in FIG. 3 , in which identical elements bear the same references, the bore 24 b of the socket has a first group of striations or grooves 36 made axially on one side of the socket and a second group of striations or grooves 38 made axially on the opposite side of the socket. In the embodiment shown, the grooves 36, 38 are identical. The grooves 36, 38 extend radially outwards from the bore 24 b of the socket. The grooves 36, 38 may be formed on the bore 24 b of the socket by knurling.

In the embodiment shown, the grooves 36 open out on the end face 24 c of the socket and the grooves 38 open out on the end face 24 d. As a variant, the grooves 36, 38 could be formed such that they do not open out on these end faces. The groups of grooves 36, 38 are spaced apart axially. The grooves 36, 38 of a group are immediately adjacent in the circumferential direction. As a variant, only the grooves 36 or the grooves 38 could be provided.

As in the first example described, the insulating liner of the device equipped with this socket 24 comprises a plurality of protuberances formed during overmolding thereof and each extending into one of the grooves 36, 38 and having a shape complementary to the associated groove.

In the embodiment shown in FIG. 4 , the recesses in the bore 24 b of the socket are made in the form of axial grooves 40 spaced apart from one another in the circumferential direction, in this case regularly. The grooves 40 extend axially along the bore 24 b of the socket and open out on the two end faces 24 c, 24 d. Alternatively, the grooves 40 may not open out on at least one of the end faces 24 c, 24 d.

The embodiment shown in FIG. 5 differs from the previous example in that the grooves 42 on the bore 24 b of the socket extend helically.

As in previous examples, the insulating liner of the device equipped with this socket 24 comprises a plurality of protuberances formed during overmolding thereof and each extending into one of the grooves 40, 42 and having a shape complementary to the associated groove.

In the above embodiments, the bore 24 b of the socket has recesses to retain, in the circumferential direction, the insulating liner 26 relative to the outer surface by complementarity of shapes with the protuberances of the insulating liner. As a variant, the arrangement of the recesses and the protuberances on the socket and on the insulating liner may be reversed.

For example, in the embodiment shown in FIGS. 6 and 7 , in which identical elements bear the same references, a first group of radial protuberances 44 is made axially on one side of the socket 24, and a second group of radial protuberances 46 is made axially on the opposite side of the socket. The protuberances 44, 46 protrude radially inwards relative to the bore 24 b of the socket. The protuberances 44, 46 form radial protrusions.

The protuberances 44 of the first group are located axially close to the end face 24 c of the socket. The protuberances 44 are formed from the end face 24 c by locally pushing back material and are located on the bore 24 b.

The protuberances 46 of the second group are located axially close to the end face 24 d of the socket. Like the protuberances 44, the protuberances 46 are formed from the end face 24 d by locally pushing back material.

The protuberances 44, 46 are in this case identical. By way of indication, it is possible to envisage protuberances 44, 46 extending over an angular sector of between 5° and 15°.

In the embodiment shown, the protuberances 44, 46 of a group are regularly spaced apart from one another in the circumferential direction but an irregular spacing is also possible. In another variant embodiment, a single annular or non-annular protuberance could be provided on each side of the socket.

In the embodiment shown, each protuberance 44 of a group is aligned in the circumferential direction with one of the protuberances 46 of the other group. In the alternative, the protuberances 44 may be circumferentially offset relative to the protuberances 46.

After overmolding of the insulating liner 26 on the outer ring 14 of the bearing and on the socket 24, each protuberance 44, 46 extends into a notch 48, 50 made on the outer surface of the insulating liner. The protuberances 44, 46 on the socket have a shape complementary to the shape of the notches 48, 50 in the insulating liner. The notches 48, 50 in the insulating liner are formed during overmolding. The protuberances 44, 46 extend into the electrically insulating material of the insulating liner 26. The protuberances 44, 46 are entirely embedded in the electrically insulating material.

In the above embodiments, the bore 24 b of the socket has recesses or protuberances to prevent rotation of the insulating liner 26 and are an example of means for preventing rotation of the insulating liner 26. Alternatively or in combination, other configurations of the bore 24 b of the socket may be used to angularly retain the insulating liner 26 relative to the outer surface 14 a by complementarity of shapes.

For example, in the embodiment shown in FIG. 8 , in which identical elements bear the same references, the axis 52 of the inner bore 24 b of the socket is offset radially relative to the axis X-X′ of the outer ring 14 of the bearing. The outer surface 24 a of the socket is cylindrical and has an axis X-X′. The outer surface 26 a of the insulating liner has a shape complementary to the bore 24 b of the socket. The outer surface 26 a has a cylindrical shape and an axis 52.

As stated above, in the embodiments shown, the first ring 12 of the bearing is the inner ring and the second ring 14 on which the insulating liner 26 is overmolded is the outer ring. Alternatively, it is possible to envisage a reverse arrangement in which the second ring 14 on which the insulating liner 26 is overmolded is the inner ring. In this case, the insulating sleeve is located in the bore 12 a of the inner ring. The insulating liner is then interposed radially between the bore 12 a of the inner ring and the outer surface of the socket. The insulating liner is overmolded on the inner ring and at least on the bore of the socket. The bore of the socket delimits the bore of the bearing device.

In the embodiments described, the bearing of the device has a single row of rolling elements. The bearing may as a variant have several rows of rolling elements. Furthermore, the rolling bearing may include other types of rolling elements other than balls, for example rollers. In another variant, the bearing may be a sliding bearing without any rolling elements.

Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved bearings having integrated electrical insulation.

Moreover, combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.

All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter. 

What is claimed is:
 1. A bearing device comprising: a bearing including a first ring and a second ring mounted for relative rotation; and an insulating sleeve mounted on the second ring, the insulating sleeve comprising a socket and an electrically insulating liner contacting the second ring, wherein the socket includes an outer surface and an inner surface opposite the outer surface, the outer surface and the inner surface delimiting a radial thickness of the socket, wherein the insulating liner is overmolded on the second ring of the bearing and on the outer surface and/or the inner surface of the socket, wherein the socket and the insulating liner are shaped such that the insulating liner is prevented from moving circumferentially relative to the socket.
 2. The bearing device according to claim 1, wherein the inner surface of the socket has at least one recess and the insulating liner includes at least one protuberance extending into the at least one recess, and wherein a shape of the at least one protuberance is complementary to a shape of the at least one recess.
 3. The bearing device according to claim 2, in which the at least one recess comprises at least one notch.
 4. The bearing device according to claim 2, in which the at least one recess comprises at least one groove.
 5. The bearing device according to claim 4, in which the at least one groove is linear and extends axially.
 6. The bearing device according to claim 4, in which the at least one groove extends helically.
 7. The bearing device according to claim 1, wherein the outer surface of the socket and/or the inner surface of the socket has at least one protuberance protruding into at least one notch in the insulating liner, the at least one notch having a shape complementary to a shape of the at least one protuberance.
 8. The bearing device according to claim 1, wherein the outer surface of the socket is cylindrical and has a central longitudinal axis, wherein the inner surface of the socket is cylindrical and has a central longitudinal axis, and wherein the central longitudinal axis of the outer surface is radially offset relative to the central longitudinal axis of the inner surface.
 9. The bearing device according to any claim 1, wherein the socket is made of metal.
 10. The bearing device according to claim 1, wherein the socket and the insulating liner are connected by an interference fit.
 11. The bearing device according to claim 1, wherein a portion of the socket extends radially into the insulating liner and/or a portion of the insulating liner extends radially into the socket to prevent rotation of the socket relative to the insulating layer.
 12. An electric motor comprising: a housing, a shaft, and at least one bearing device according to claim 1 mounted radially between the housing and the shaft.
 13. A bearing device comprising: a bearing including a first ring mounted for rotation relative to a second ring; an insulating sleeve including a socket and an electrically insulating liner, the electrically insulating liner being overmolded on socket and the second ring; and means for preventing circumferential movement of the insulating liner relative to the socket. 